Flexible Sensor Element for Tire Tread Wear Detection
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Solution Overview
Problem
Existing tire technologies face challenges in detecting tread abrasion without impairing the tire's structure or performance, as external sensor elements can create breaking points and require additional space with different material compositions.
Innovation Solution
Integration of a flexible sensor element with a conductive structure into the tire structure during the manufacturing process, using printed electronics, which adapts to the tire's contours and materials, allowing for non-invasive wear monitoring without altering the tire's running properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor elements are subsequently introduced into the tire (e.g., abrasion pins), then tread wear can be detected, but the tire structure is impaired with predetermined breaking points and driving properties are compromised
Solution Approach 1:
The sensor element is merged with the tread structure by integrating it into the tire construction components during manufacturing. The flexible carrier with conductive structure is embedded in the tread strip, making the sensor element an integral part of the tire rather than an external addition, thus eliminating predetermined breaking points while maintaining structural integrity
Solution Approach 2:
The sensor element uses a flexible carrier made of elastomer or polymer material with elasticity adapted to match the rubber mixture of the tread strip. This parameter adaptation ensures the sensor element integrates seamlessly with the tire structure, maintaining homogeneous mechanical properties and avoiding stress concentrations that would compromise reliability
2Measurement precision
If sensor elements are subsequently introduced into the tire, then wear detection is enabled, but additional space is required and material composition must differ from tread material
Solution Approach 1:
The carrier is designed with thickness between 0.5 mm and 1 mm, making it very thin to minimize space occupation. The material composition is adapted to match the tread rubber mixture, allowing the sensor element to be integrated without requiring significant additional space or creating material heterogeneity that would affect tire performance
Solution Approach 2:
The sensor element uses a flexible carrier that can be made very thin (0.5-1 mm), functioning as a thin film that embeds the conductive structure while occupying minimal space within the tire construction components. This thin-film approach enables wear detection without significantly increasing the quantity of substance or displacing actual tire material
3Stability of the object's composition
If a rigid sensor element is used, then structural stability is maintained, but the sensor cannot adapt to tire contours and creates cavities or stresses
Solution Approach 1:
The sensor element employs a flexible carrier made of elastomer or polymer material that can conform to the contours of the tire and tire construction components. This flexibility allows the sensor to adapt to uneven surfaces and curved geometries, eliminating cavities and stress concentrations while maintaining reliable electrical contact and structural integration
Solution Approach 2:
The flexible carrier enables the sensor element to dynamically adapt its shape to match the tire's contours and deformation during operation. The elasticity of the carrier allows it to flex with the tire, maintaining intimate contact with the support surface and ensuring continuous reliable electrical properties for wear detection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable and unobtrusive tread abrasion detection, ensuring the tire's performance and longevity by embedding the sensor element within the tire, which wears down with the tread, eliminating the need for additional components and minimizing material displacement.
Implementation Method 1
the resistance being correlated with the abrasion, so that the abrasion level of the tread strip can be deduced from a measurement of the resistance
Data Source
Figure 1~2d
AI summary
The invention relates to a tire (1), wherein the tire (1) is formed by several tire construction components (2, 3, 4, 5, 6, 7, 8) and at least one sensor element (9) is arranged in the tire construction components (2, 3, 4, 5, 6, 7, 8) in such a way that the abrasion height (A) of the tread (2) of the tire (1) can be determined via the at least one sensor element (9), wherein for this purpose an electrical measurement quantity characterizing the electrical property of the at least one sensor element (9) can be detected via a signal-conducting connection (10), and the abrasion height (A) of the tread (2) can be determined from a temporal behavior of the detectable electrical measurement quantity of the respective sensor element (9).According to the invention, the at least one sensor element (9) has a planar, flexible carrier and at least one conductive structure is deposited on the carrier, wherein the detectable electrical measurement characterizes the electrical property of the at least one deposited conductive structure on the carrier, and the flexible carrier with the deposited conductive structure is arranged in the tire construction components (2, 3, 4, 5, 6, 7, 8) such that a change in the electrical measurement over time can be used to determine the wear height (A) of the tread (2). The invention further relates to a method for manufacturing such a tire (1).